Optimizing the mechanical properties of Al-SS joint using the numerical and experimental investigation of electromagnetic welding

Abstract

In this research, the influence of electromagnetic welding (EMW) parameters such as voltage (V), standoff distance (Ds) and distance between spacers (Sd) on ultimate tensile strength (UTS), elongation (El), weld length (Wl) and hardness (HV) of Al-SS joint has been investigated. Formation of Al-SS weld was predicted using the finite-element analysis (FEA) in combination with the weldability window. The experimental tests were performed using the response surface methodology (RSM) to develop the regression equations based on the significant parameters. For evaluating the quality of joints, the microstructure of weld interface was studied by optical and scanning electron microscopy (SEM). It was observed from the results that the maximum ultimate tensile strength (UTS), elongation (El), weld length (Wl) and hardness (HV) of Al-SS weld can be obtained simultaneously by the voltage of 11.2 kV, standoff distance of 1.9 mm and distance between spacers of 22.5 mm.